Utility carrier end mounted replaceable baseboard heater

ABSTRACT

An electric baseboard heater having an elongated rod-type heating element supported between a backwall and a demountable front wall is provided with an end-loaded utility carrier. The carrier includes an end wall defining the end wall of the heater, a web section integral with the end wall and extending along the heater backwall and a heater-component mounting wall integral with the web section spaced inboard a substantial distance from the end wall and projecting forwardly from the web section. The component mounting wall includes means for mounting an end of the heating element and for mounting the front wall of the heater. A forwardly extending channel is provided along the heater backwall and provides means for accommodating the screws for securing the utility carrier and the intermediate heating element supporting brackets to the backwall. The utility carrier can accommodate such accessories as a relay, thermostatic switch, female electrical receptacle, transfer switch, etc.

.United States Patent 3,152,241 10/1964 Ammerman................. 3,165,624 l/I965 Cunningham 3,448,243 6/1969 Ripp1e.............. 3,470,351 9/1969 Fscher.....

Primary Examiner-A. Bartis Attorney-Polster and Polster PATE- MED F592 3 1971 v l vGQ15651077 SHEET u UF 4 i UTILITY CARRIER END MOUNTED REPLACEABLE BASEBOARI) HEATER BACKGROUND OF THE INVENTION Baseboard heaters in common use have an elongated rodtype electric heating element, a channel-shaped front wall which shields the heating element from outside objects, a backwall which is generally mounted flush against a building wall, and two end walls. Generally, an inner rod-supporting wall is welded to the inside (forward) face of the backwall in inboardly spaced relation to each end wall, which is also welded or otherwise secured to the backwall. The space between the inner wall and the end wall at each end constitutes a junction box. Heretofore, if attachments, as, for example, a variable thermostatic control or utility outlet are to be provided, a separate box, constituting in effect an extension ofthe heater, has been mounted on the end wall of the heater. In such an arrangement, the overall length of the heater is increased by 8 inches or so, which means that allowance for such an addition must be made.

In still another type of heater, a separate cover is provided which is mounted and demounted from the front. In this type, as well as in the type in which an extra box is attached, the line of the front wall is interrupted. In the second form, the cover can also be removed as by a child.

One of the objects of this invention is to provide a baseboard heater with a utility carrier which serves as a junction box but which is more versatile than junction box arrangements known heretofore.

Another object is to provide such a baseboard heater which is economical to manufacture, attractive in appearance, easy to install, tamper resistant and of uniform length.

Other objects will become apparent to those skilled in the art in the light of the following description and accompanying f drawings.

SUMMARY OF THE INVENTION In accordance with this invention, generally stated, in an electric baseboard heater having an elongated rod-type heating element, a backwall and a demountable front wall, an endloading utility carrier is provided, which includes as a unit a heater end wall-defining end wall, a web section integral with the end wall and extending along the backwall of the heater and a heater-component mounting wall integral with the web section and spaced inboard of the heater a substantial distance from the end wall and projecting forwardly from the web section. Means are provided on the mounting wall for mounting an end of the heating element and for mounting the front wall of the heater, and means are provided for mounting the carrier in the end of the heater. Preferably, the heater is provided with a forwardly extending channel in its rear surface, and the mounting means for the carrier include a` sheet metal screw projecting through an opening in the carrier and through the backwall into the channel. The channel thus provides a means of accommodating sheet metal screws andthe like for mounting not only the utility carrier but also the heating element rod-supporting bracket intermediate the carrier, while still permitting the areas of the backwall contiguous the channel to be mounted flush against the building wall.

BRIEF DESCRIPTION OF THE DRAWINGS In the drawing, FIG. I is a fragmentary view in front elevation, partly broken away, of a baseboard heater provided with one embodiment of utility carrier of this invention;

FIG. 2 is a view in end elevation of the heater shown in FIG. i, with internal parts, including the utility carrier shown in FIG. i, in dotted lines;

FIG. 3 is a fragmentary view in front elevation, partly broken away, of a baseboard heater provided with a utility carrier of this invention, which differs from the utility carrier means for mounting different accessories;

FIG. 4 is a view in end elevation of the heater shown in FIG. 3;

FIG. 5 is an exploded, fragmentary view in perspective of an end of a heater and one embodiment of utility carrier;

FIG. 6 is a view in (inside) a end elevation of the utility carrier shown in FIG. 5;

FIG. 7 is a view in front elevation of the utility carrier shown in FIGS. 5 and 6; and

FIG. 8 is a view in (outside) end elevation of the utility carrier shown in FIGS. 5 and 7.

Referring now to the drawing for illustrative embodiments of the utility carrier of this invention, in which drawings like numbers will represent elements common to all embodiments, reference number I indicates a base board heater of the character shown and described in my copending application, Ser. No. 779,850, filed Nov. 29, 1968 The baseboard heater l has a backwall 10, a front 30 and an end wall which forms a part of the utility carrier of this invention. The heater has another end wall, not here shown, which forms a part of a utility carrier which can be a mirror image of the utility carriers illustrated in various figures. The baseboard heater also has an electric heating element 60 which is relatively small in diameter, i.e., laterally narrow, and long, has fins 61 spaced along and tightly mounted on it, and ends 62. Only one end 62 is shown, but the ends at both extremities are identical.

The backwall l0 is provided along its rear surface with a channel 17 which extends the full length of the backwall and through approximately the height of the fins 61, and which provides a corresponding embossment 19 on the forward surface of the backwall. The embossment 19 is cut away at each end a short distance to accommodate a part of the utility carrier as explained hereinafter.

The front wall 30 in all of the illustrative embodiments has an unbroken sweep from end to end of the heater. lt has afoot 3l which fits into a channel 20, a lower section 32 which is perforated to from a grille, an imperforate center section 34, an upper section 36 and an imperforate baffle 37.

Between the lower section 32 and the center section 34 is a dogleg 33. Between the center section 34 and the upper section 36 is a ledge 3S.

The embodiments of utility carrier shown differ chiefly in minor variations in the end wall construction and openings or knockouts for accommodating different arrangements of equipment to be mounted in the utility carrier.

Referring now to FIGS. 5 8 for one illustrative embodiment of utility carrier of this invention, reference number indicates a utility carrier, having a housing end wall-defming end wall 110, a bridging wall 130 and a heater componentmounting inside wall 170. The end wall 110, has a top tab 111, a lip tab 113 which is spaced from the top tab 111, and a channel tab 112. A front edge 114 of the end 110 is profiled to complement the profile of the lower part of the front wall 30 of the heater, although the end wall projects slightly beyond the front wall, as shown in FIGS. 2 and 4. The upper part of the front edge of the end wall extends in a straight line to the `top of the heater, forming an end closure for the space defined by the top of the heater and the upper section 36 of the front wall. A back edge 116 of the end wall is substantially vertical and forms an end closure from a point immediately adjacent the bottom of the channel 20 to a top wall l1 of the heater.

In the embodiment of utility carrier 100 shown in FIGS. 5- -8, two large openings 120 and two screw-receiving openings 121 are provided in the end wall 110.

Referring now to FIGS. 6, 7 and 8, as well as FIG. 5, a connecting wall 125, integral at one edge with the end wall 110 along a part of the back edge 116, is integral along another edge with the bridging wall 130. The connecting wall 12S and bridging wall together constitute a web section joining the end wall 110 and inside wall 170. The connecting wall 125 is bent forwardly, so that the bridging wall 130 is perpendicular to the end wall 110 but offset forwardly from the rear edge 116. Two vertically spaced clips 126 are lanced from the bridging wall 130 and connecting wall 125. The clips 126 have provided to accommodate a Tinnerman clip for securing the` front wall 30 of the housing. The margin section 132 is offset forwardly of a center section 133 of the bridging wall. The center section 133 of the bridging wall 130 extends in a direction away from the end wall .110 farther than the upper 'Y marginal part 132, and is formedintegrally at its laterally outer edge with the inside wall 170. Extending from that edge toward the end wall 110 is an open-ended slot 135, at the mouth of which the inner wall 170 is cut away to admit the head of a sheet metal screw 133. The bridging wall 130 is also provided with knockouts orl openings adapted to receive electrical components or leads, and small holes to receive sheet metal screws. The inner wall 170 is lanced to provide a screwreceiving salient 174, to hold a cover, not here shown. The inner'wall 170 has in its forward edge an upper ear 171 and a lower ear 172, between which is a U-shaped, open-mouthed opening 173, in which an insulating bushing 180 is seated. The insulating bushing 180 has grooves 181in its long sides, within which the edges defining the opening 173 seat, to retain the bushing 180 against lateral displacement. The bushing 180 has a hole 183 in it, in which an end of the' the heating element 60 is seated and through which the end of the heating element passes.

In its simplest form, without any extra components, as shown n'FIG. 5, the utility carrier is shoved into the housing of the heater, the top tab 111 passing closely against but beneath the top of the housing and the lip tab 113 passing into the channel defined bythe lip 13, the channel tab 112 entering the channel 20, and the clips 126 engaging the end edge of the embossment 19. The connecting wall 125 fills the space produced by the cutting away of the embossment 19, and at the same time, the cut away part of the end of the embossment permits the end wall of the utility carrier to butt against `the rest of the end of the housing. The end of the heating element 60 passes through the opening 181 in the bushing 180. It can be seen that if it is desired, the bushings 180 can be placed on the ends of the heating elements and then slid into position in the opening 173, after the utility carriers are installed.

In the embodiment shown, the sheet metal screw 138, can have been vmounted but not tightened in the embossment 19, the head of the screw, which has passed through the opening in the wall 170 while its shank is embraced between the edges of the slot 13S, can be tightened to hold the end in place. The

frictional engagement of the tabs 113 and 112 in their respective channels, will generally be sufficient in any case.

Cover 190 can be mounted temporarilyhy means of a sheet metal screw screwed into the screw-receiving salient 174.

The front wall 30 can be mounted by snapping the dogleg 34 and ledge 35 over the ears 172 and 171, respectively.

When the baseboard heater is to be mounted, the front 30 and cover 190 can be removed and the heating element 60 electrically connected, through the holes in the bridging wall 130 or through the end wall, to a source of current, and the cover 190 and front 30 of the heater replaced.

Referring now to FIGS. 1 and 2 which illustrate the utility carrier with additional electrical components mounted in and on it, reference numeral 201 indicates a low-voltage relay, electrically connected to a wall thermostat, not here shown,

' by means of electrical conductors 202, which pass through an insulating bushing 203 in a wall of a subjunction box 204. The subjunction box 204 is a part of a mounting bracket, on which the low-voltage relay is also mounted, so that the entire assembly may be mounted on the utility carrier by means of a sheet metal screw205 before the utility carrier is mounted in the housing. The sheet metal screw 205 extends through the bridging wall above the embossment 19 the offset of the embossment providing a pocket within which the sheet metal screw 20S can project.

In FIGS. 3 and 4, an end wall 310 is identical to the wall 110 except for the shape of openings in the wall, which in the embodiment shown in FIGS. 3 and 4, accommodate a rectangular transfer switch 320 and a round transfer switch receptacle 330. The transfer switch 320 is connected electrically to a source of 240 volt AC current, to the resistance element of the heater 62, and the receptacle 330. With this arrangement, a room airconditioner can be plugged into the receptacle 330, the switch 320 being so constructed as to supply energy selectively to the element 62 or the receptacle 330. The electrical connections, forming no part of this invention, are not illustrated.

Numerous variations in the construction of the ,utility carrier of this invention within the scope of the appended claims will occur to those skilled in the art in the light of the foregoing disclosure. For example, a thermostatic control, housed in the utility carrier, can have a setting stem projecting through a hole in the end'wall, or, oriented vertically, through a slot in the cover and one of the openings in the grill of the front. Wireway bushings or conduit canbe mounted through adjacent ends of a row of heaters. A cylindrical bushing can be provided, seated in a hole in the inside wall 170, to receive the end of the heater element, but the advantage of being able to install utility carriers at both ends of the heater before installing the heating element would be lost. The parts of the utility carrier can be riveted,l bolted, welded or otherwise joined. although such an arrangement loses the advantage of simplicity and economy in mass production. These are merely illustrative.

Iclaim:

1.A In an electric baseboard heater having an elongated rodtype heating element, a backwall and a demountable front wall, the improvement comprising an end-loading utility carrier, said carrier comprising a heater end wall-defining end wall with at least one opening therein, a web section integral with said end wall and extending along the backwall of the heater, and a heater-component mounting wall integral with said web section, means on said mounting wall for mounting an end of said heating element, means on said mounting wall lfor mounting the front wall of the heater, means for demountably and remountably mounting the carrier in the end ofthe heater and at least one accessory mounted within said carrier and having a female electric receptacle with electrical connections within said carrier and mounted with outwardly oriented sockets at said end wall opening.

2. ln an electric baseboard heater having an elongated heating element, a backwall with a forward projecting embossment along its length and a demountable front wall, the improvement comprising an end-loading utility carrier, said carrier comprising a heater end wall defining end wall, a web section connected to said end wall by a connecting wall, and a heatercomponent mounting inside wall connected to said web section, spaced inboard of the heater a substantial distance from the end wall and projecting' forwardly from said web section, said web section being offset forwardly complementarily to said backwall embossment and extending along said embossment, and said connecting wall sloping rearwardly from said web section, said embossment portion of said backwall of the heater being cut away at an end in which said utility carrier is mounted to accommodate said connecting wall and to provide with said connecting wall and said carrier end wall an end closure, means on said inside wall for mounting an end of said heating element, and means on said carrier for selectively demountably and remountably mounting said carrier in the end of the heater. 

1. In an electric baseboard heater having an elongated roD-type heating element, a backwall and a demountable front wall, the improvement comprising an end-loading utility carrier, said carrier comprising a heater end wall-defining end wall with at least one opening therein, a web section integral with said end wall and extending along the backwall of the heater, and a heater-component mounting wall integral with said web section, means on said mounting wall for mounting an end of said heating element, means on said mounting wall for mounting the front wall of the heater, means for demountably and remountably mounting the carrier in the end of the heater and at least one accessory mounted within said carrier and having a female electric receptacle with electrical connections within said carrier and mounted with outwardly oriented sockets at said end wall opening.
 2. In an electric baseboard heater having an elongated heating element, a backwall with a forward projecting embossment along its length and a demountable front wall, the improvement comprising an end-loading utility carrier, said carrier comprising a heater end wall defining end wall, a web section connected to said end wall by a connecting wall, and a heater-component mounting inside wall connected to said web section, spaced inboard of the heater a substantial distance from the end wall and projecting forwardly from said web section, said web section being offset forwardly complementarily to said backwall embossment and extending along said embossment, and said connecting wall sloping rearwardly from said web section, said embossment portion of said backwall of the heater being cut away at an end in which said utility carrier is mounted to accommodate said connecting wall and to provide with said connecting wall and said carrier end wall an end closure, means on said inside wall for mounting an end of said heating element, and means on said carrier for selectively demountably and remountably mounting said carrier in the end of the heater. 